Carbon fiber wall reinforcement system and a method for its use

ABSTRACT

The basement wall reinforcement system comprises carbon fiber materials securely mounted to the wall being reinforced as well as to structural components at both the top and bottom of the wall. These additional connections at the top and bottom of the wall increase the capacity of the carbon fiber to prevent bowing and cracking by transferring lateral forces from the wall to these structural components. Such structural components can include foundations, basement floors, sill plates, rim joists and floor joists. The carbon fiber can be connected to these structural components by pins, epoxies and specially designed brackets.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 13/006,408filed on Jan. 13, 2011, which claims benefit to provisional applicationno. 61/294,622, which are both incorporated by reference herein in theirentireties.

FIELD OF THE INVENTION

The present carbon fiber wall reinforcement system is an improvementover existing carbon fiber devices used to support basement andfoundation walls and prevent bowing and cracking. While it is known thatcarbon fiber strips can be mounted on a basement wall to provide lateralsupport, the attachments used at the top and bottom of each carbon fiberstrip must also provide sufficient force resistance to prevent failureat these locations. A woven carbon fiber pin or similar pin can beconnected to the floor and foundation to provide support at thatlocation and a sill plate bracket can be used at the top of the wall toprovide reinforcement by connecting the carbon fiber strip to the sillplate or similar structural feature of the building.

BACKGROUND

The basement walls of any building must support the weight of the entirebuilding. Such walls are typically made from poured concrete orcinderblocks, which both have a very high resistance to the compressionforces created by the weight of the building. However, these materialsprovide very little resistance to lateral forces created by soil andwater pushing against the outside surface of the wall. With little or nosupport on the inside of the wall to counteract these forces, it must becapable of bearing these lateral loads itself. However, in manyinstances, these walls cannot withstand the magnitude of these lateralforces and can begin to bow and crack.

Many techniques have been created to combat the effects of lateralforces on basement walls. Specifically, when a basement wall isconstructed, rebar or metal beams are routinely inserted into theconcrete as it is poured, or as the cinder block basement walls arebuilt. This metal provides some resistance to lateral forces, but it isoften insufficient to counter strong lateral forces by itself.Additionally, these types of solutions cannot be installed after a wallhas been constructed, and therefore, cannot be used to reinforce a wallafter it has already been compromised by lateral forces.

Steel beams have been used to reinforce the interior sides of basementwalls after they have begun to bow or crack. However, steel beams can belarge and unsightly when installed along a basement wall. This can beunacceptable in finished basements, which are commonly found in modernhomes and office buildings.

In order to create a more aesthetically pleasing solution to thisproblem, carbon fiber has been applied to wall surfaces in thin strips,which can be painted, in order to resist lateral forces exerted againstthe outside of the wall. Carbon fiber is a very strong material, whichhas proven capable of supporting basement walls subjected to extremelateral forces. However, when carbon fiber is placed only on the surfaceof a wall, stress points can be created at the top and the bottom of thewall, where there continues to be no reinforcement. One solution to thisproblem has been to attach a Kevlar strap from the carbon fiber strip toa floor joist located above where the strip has been installed. Thisstrap can reduce some of stress created at the top of the wall where thecarbon fiber strip ends, but still allows shifting to occur and does notaddress the fact that there remains no support at the bottom of thewall.

What is needed is a system for reinforcing a basement wall, which candisperse the lateral forces throughout the entire wall as well as thebuilding above it and the floor and foundation below it. These forcescan be dispersed if there is a good connection between the carbon fiberstrips and both the lower portion of the building located on the top ofthe basement wall and the basement floor and foundation at the bottom ofthe basement wall.

SUMMARY OF THE INVENTION

It is an aspect of the present device to provide a system to reinforce abasement wall that disperses the lateral forces throughout the entirewall including the top, bottom or both the top and bottom of the wall.

The above aspect can be obtained by a basement wall reinforcement systemcomprising: one or more carbon fiber strips having a first end and asecond end, wherein the first end is located at a bottom of a basementwall and the second end is located above a top of the basement wall at alower portion of a building; a pin connected to the first end of thecarbon fiber strip; a hole at the base of the basement wall capable ofaccepting the pin; and a sill plate bracket assembly capable of securelyconnecting the second end of the carbon fiber strip to the lower portionof a building.

The above aspect can also be obtained by a basement wall reinforcementsystem comprising: one or more carbon fiber strips having a first endand a second end, wherein the first end is located at a bottom of abasement wall and the second end is located above a top of the basementwall at a lower portion of a building; a pin connected to the first endof the carbon fiber strip; and a hole at the base of the basement wallcapable of accepting the pin.

The above aspect can also be obtained by a method for reinforcing abasement wall comprising: providing one or more carbon fiber stripshaving a first end and a second end, epoxy, one or more pins, eachcapable of being connected to the first end of the carbon fiber strip,one or more holes at the base of the basement wall capable of acceptingthe pin, and a sill plate bracket assembly capable of securelyconnecting the second end of the carbon fiber strip to a lower portionof a building; and installing such that one or more carbon fiber stripsis connected to the basement wall with epoxy; each pin is connected bothto the first end of a carbon fiber strip; each pin is also securelyconnected to a hole with epoxy; and the second end of the carbon fiberstrip is securely connected to the lower portion of a building with asill plate bracket assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features and advantages of the present device, as well as thestructure and operation of various embodiments of the present device,will become apparent and more readily appreciated from the followingdescription of the preferred embodiments, taken in conjunction with theaccompanying drawings of which:

FIG. 1 is a cut-away view of a basement wall comprising no additionalstructural support;

FIG. 2 is a cut-away view of a basement wall equipped with a carbonfiber wall reinforcement system comprising reinforcements at both thetop and bottom of the basement wall, according to an embodiment;

FIG. 3A is a front view of a carbon fiber strip connected to a pin,according to an embodiment;

FIG. 3B is a close-up view of the bottom section of a carbon fiberstrip, connected to a pin, according to an embodiment;

FIG. 4 is a top perspective view of a sill plate bracket which can beused to attach a carbon fiber strip to a sill plate or similarstructural feature, according to an embodiment;

FIG. 5 is a perspective side view of a sill plate bracket which can beused to attach a carbon fiber strip to a sill plate or similarstructural feature, according to an embodiment;

FIG. 6 is a cut-away view of a basement wall, wherein a hole forinstalling a pin has been drilled into a corner where a basement floorabuts the basement wall, according to an embodiment;

FIG. 7 is an exploded perspective view of the top of the carbon fiberstrip showing how it can be attached to a sill plate using a sill platebracket and lag bolts, according to an embodiment;

FIG. 8 is a cut-away view of a pin inserted into a hole in a cornerwhere a basement floor abuts a basement wall, wherein the pin has beensecurely mounted in the hole with an epoxy, according to an embodiment;and

FIG. 9 is a perspective view of basement wall supported by severalcarbon fiber wall reinforcement systems, wherein each can be securelyconnected at both the top and bottom of the basement wall, according toan embodiment.

DETAILED DESCRIPTION

This description of the exemplary embodiments is intended to be read inconnection with the accompanying drawings, which are to be consideredpart of the entire written description. In the description, relativeterms such as “lower,” “upper,” “horizontal,” “vertical,”, “above,”“below,” “up,” “down,” “top” and “bottom” as well as derivative thereof(e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should beconstrued to refer to the orientation as then described or as shown inthe drawing under discussion. These relative terms are for convenienceof description and do not require that the apparatus be constructed oroperated in a particular orientation. Terms concerning attachments,coupling and the like, such as “connected” and “interconnected,” referto a relationship wherein structures are secured or attached to oneanother either directly or indirectly through intervening structures, aswell as both movable or rigid attachments or relationships, unlessexpressly described otherwise.

Reference will now be made in detail to the presently preferredembodiments of the invention, examples of which are illustrated in theaccompanying drawings, wherein like reference numerals refer to likeelements throughout.

FIG. 1 is a cutaway view of a basement wall 100 comprising no additionalsupport.

A basement wall 100 is typically located between the foundation 101 andthe sill plate 108 of a building. The exterior side 106 of the basementwall 100 is in contact with the external environment, including earthand water, which can exert significant lateral forces 104 inward againstthe basement wall 100. Additionally, compression forces are exerted onthe wall from the weight of the building being supported. An unsupportedbasement wall 100 will often buckle or crack 105 at its middle or at anypoint of weakness along the height of the wall. The wall 100 istypically weakest at its middle because that is where it receives theleast amount of lateral support from either the basement floor 107 andfoundation 101 at its bottom or the weight of the building through thesill plate 108 and floor joists 102 at its top.

FIG. 2 is a cut-away view of a basement wall 100 equipped with a carbonfiber wall reinforcement system 206 comprising reinforcements at boththe top 210 and bottom 211 of the basement wall 100, according to anembodiment.

The present carbon fiber wall reinforcement system 206 can comprise acarbon fiber strip 207 connected to the interior surface 217 of thebasement wall 100, which can act to support the wall 100 and help itresist buckling and cracking due to lateral forces 104 exerted againstthe exterior side 216 of the wall 100. The use of carbon fiber strips207 to reinforce basement walls is known. However, mounting one or morecarbon fiber strips to the surface of a wall 100 can transfer additionallateral forces, to both the top 210 and bottom 211 of the wall 100,which is not reinforced by the addition of the carbon fiber strip 207alone. The result being failure of the wall 100 at either its top 210 orbottom 211.

The present carbon fiber wall reinforcement system 206 can solve thisproblem by providing additional support at both the top 210 and thebottom 211 of the basement wall 100. The bottom 211 of the wall 100 canbe reinforced by securely connecting the carbon fiber strip 207 to thefoundation 101 or basement floor 107 through the use of a pin 212, orsimilar device known to those of ordinary skill in the art ofmanufacturing building materials. The top 210 of the wall 100 can bereinforced by securely connecting the carbon fiber strip 207 to a lowerportion of a building, which can include the sill plate 108, floorjoists 102, rim joist (not pictured), or other similar structuralfeature using a specially designed sill plate bracket assembly 214.

FIG. 3A is a front view of a carbon fiber strip 207 connected to a pin212, according to an embodiment.

The carbon fiber strip 207 can be approximately 4 to 12 inches wide in apreferred embodiment and can be any length necessary to reach from thebottom of the basement wall (not pictured) to the sill plate (notpictured). The carbon fiber strip 207 can be cut to fit any wall heightprior to being installed, but will typically be 8 to 10 feet in length.In a preferred embodiment, the carbon fiber fabric comprising both thecarbon fiber strip 207 and the pin 212 can be woven andmulti-directional, but unidirectional carbon fiber fabric can also beused. In a preferred embodiment, the carbon fiber strip 207, the pin212, or both can be comprised of one piece of carbon fiber fabric.However, in an alternative embodiment, the carbon fiber strip 207, thepin 212, or both can be comprised of more that one piece of carbon fiberfabric.

In a preferred embodiment, the pin 212 can be 1 to 3 inches in diameterwhere it connects to the strip 206 and taper down to a diameter of ¼ to1½ inches at its tip end 316 and can be approximately 6 to 12 inches inlength. Although these dimensions are preferred, other suitabledimensions can be used so long as they are sufficient to counteract thelateral forces being exerted on the wall being reinforced.

FIG. 3B is a close-up view of a bottom section of a carbon fiber strip206, connected to a pin 212, according to an embodiment.

The pin 212 can be an extension of the carbon fiber strip 207, whereinthe pin 212 is formed by twisting the bottom of the carbon fiber strip207 thereby creating a taper and pointed tip end 316, which can then beset and hardened with an epoxy. In an alternative embodiment, the pin isnot hardened with an epoxy, but is placed into the hole dry and epoxy isthen injected into the hole. In addition to providing a seamlessconnection to the carbon fiber strip 207, the taper and pointed tip end316 of the pin 212 can ease its insertion into a hole drilled at thebottom 211 of the basement wall where the carbon fiber strip 207 isbeing installed. In an additional alternative embodiment, the pinsection 212 can be loose carbon fiber rather than be twisted, which canbe hardened and solidified during the installation process. In otheralternative embodiments, the pin section 212 can be comprised of one ormore metals, polymers, fabrics, or any other suitable material known tothose skilled in the art, which is sufficiently strong and can beconnected to a carbon fiber strip 207. This pin 212 can provideadditional strength to the bottom of the carbon fiber wall reinforcementsystem 206 thus preventing a buildup of forces at the bottom 211 of thewall 100.

FIG. 4 is a top perspective view of a sill plate bracket 214 which canbe used to attach a carbon fiber strip to a sill plate or similarstructural feature, according to an embodiment.

A sill plate bracket 214 can be used to attach a carbon fiber strip 207to a sill plate of a building. Preferably, the sill plate bracket 214can be made of stainless steel or any other suitably strong andcorrosion resistant material known to a person skilled in the art ofbuilding materials, including metals and polymers. The sill platebracket 214 can be elongated comprising two long sides 421 ofapproximately 6 inches in length and two short sides 422, ofapproximately 2 inches in length. However, any length and widthsufficient to hold the carbon fiber strip in place and attach itsecurely to the sill plate can also be used. The sill plate bracket 214can also comprise one or more pilot holes 423, wherein one can belocated at each end of the sill plate bracket 214. These holes 423 canbe ⅜ inch in diameter in a preferred embodiment and can be used inconjunction with attachment mechanisms, such as bolts, lag bolts,screws, or nails. In an alternative embodiment, the pilot holes can bereplaced by slots. The sill plate bracket 214 can also comprise twocutouts 424 which can provide the material for creating two spikes orprongs 425, which can grip a carbon fiber strip, thus allowing the sillplate bracket 214 to firmly attach the carbon fiber strip to the sillplate or a similar suitable location. The two cutouts 425 can berectangular or triangular in shape and can be one inch long in apreferred embodiment. The material from the cutout can remain attachedat the center-most edge of the opening 426 and be disconnected from thespike or prong 425 along each of its other sides. The spikes or prongs425 can also be connected to the sill plate bracket 214 separately anddo not necessarily need to be formed from the sill plate bracket 214itself.

FIG. 5 is a perspective side view of a sill plate bracket 214 which canbe used to attach a carbon fiber strip to a sill plate or similarstructural feature, according to an embodiment.

The two spikes or prongs 425, which can be formed from material cutoutfrom the sill plate bracket 214 can be folded along the attached edge426 until they are roughly perpendicular to the top surface of sillplate bracket 527. These spikes or prongs 425 can have a pointed end528, which can be pushed through the carbon fiber strip and into thesill plate. The sill plate bracket 214 can be used to hold the carbonfiber strip in place against the surface of the wall while it is securedthrough the use of an attachment mechanism.

FIG. 6 is a cut-away view of a basement wall, wherein a hole 630 forinstalling a pin has been drilled into a corner where a basement floor107 abuts the basement wall 100, according to an embodiment.

The method for installation of the carbon fiber wall reinforcementsystem can require a hole 630 to be drilled through the basement floor107 and into the foundation 101 at a slight angle, such that the hole630 extends into the foundation 101 and is located slightly below thewall 100. In some instances, particularly when the basement wall 100 iscomprised of poured concrete, the hole 630 can also pass through thebasement wall 100.

The installation of the carbon fiber wall reinforcement system can beginwith the preparation of the wall 100. The wall 100 can be marked at thelocation where the strip is to be installed. The length of the carbonfiber strip can be determined by measuring the height of the wall 100from floor to the top of the sill plate 213 and cutting the stripportion so that the flat section is equal to this height. The sill platebracket can be placed in a location on the sill plate directly above thestrip and the holes marked and drilled. In an alternative embodiment,the strip can also be connected to the sill plate 213 with epoxy. Thetop of the sill plate bracket can be level with the top of the sillplate 213. Care must be taken to mount the bracket evenly, because anuneven bracket can cause splitting and can damage the sill plate 213.The use of pre-drilled holes into the sill plate can ensure smoothmounting and installation.

FIG. 7 is an exploded perspective view of the top of the carbon fiberstrip 207 indicating how it can be attached to a sill plate 213 using asill plate bracket 214 and lag bolts 740, according to an embodiment.

An end of the carbon fiber strip 207 can be attached to the sill plate213 through the use of the sill plate bracket 214. The sill platebracket 214 can be attached to the carbon fiber strip 207. The carbonfiber strip 207 can be prepared by applying epoxy to the inside of thestrip 207, folding the end back on itself, applying epoxy again, foldingthe new end back on its self and finally adding epoxy and attaching thesill plate bracket 214. The end holding the sill plate bracket 214 isthen folded back towards the carbon fiber strip 207 and the prongs 425are pushed through the carbon fiber strip 207. The prongs 425 of thesill plate bracket 214 can face towards the sill plate 213. The sillplate bracket 214 and the carbon fiber strip 207 can be attached to thesill plate 213 through the use of two, 2 inch long lag bolts 740, whichcan each pass through a washer 741, the sill plate bracket 214, and thecarbon fiber strip 207 by inserting them into one or more pre-drilledholes 742 in the sill plate 213. Epoxy can then be applied to all sidesof the carbon fiber strip 207 to ensure a secure bond is formed with thesill plate bracket 214, the sill plate 213 and the carbon fiber support206.

The carbon fiber strip 207 can then be lifted off of the wall 100 andepoxy can be applied to the wall 100 where the carbon fiber wallreinforcement system will be installed. After the epoxy has beenapplied, the carbon fiber strip 207 can be lowered onto it and coatedwith more epoxy, saturating it on all sides. A small amount of space canbe left at the bottom of the wall to maneuver the carbon fiber pin intothe pre-drilled hole. After the pin has been installed in a hole, epoxycan be applied to the area located just above the hole.

FIG. 8 is a cut-away view of a pin 212 inserted into a hole 630 in acorner where a basement floor 107 abuts a basement wall 100, wherein thepin 212 has been securely mounted in the hole 630 with an epoxy 850,according to an embodiment.

In a preferred embodiment, the carbon fiber pin 212 can be inserted intothe drilled hole 630 in the foundation 101. The pin 212, eitherpre-hardened or flexible, can be secured in the hole 630 through the useof an epoxy 850. In either case the epoxy 850 can be placed in the hole630 and the pin 212 can be inserted into the epoxy-filled hole 630. Ifflexible, the carbon fiber can be pushed with force into the hole 630 toinsure a snug fit is achieved. The epoxy 850 can be allowed to harden,thus securing the pin 212 in place in the foundation 101.

FIG. 9 is a perspective view of basement wall 100 supported by severalcarbon fiber wall reinforcement systems 206, wherein each can besecurely connected at both the top 210 and bottom 211 of the basementwall 100, according to an embodiment.

The finished product can be painted to match the wall 100 so that it isbarely visible. To support a compromised basement wall 100, the carbonfiber wall reinforcement systems 206 can be installed approximately fourfeet apart as measured from center to center in a preferred embodiment.Additionally, in a preferred embodiment, the carbon fiber wallreinforcement systems 206 can be mounted between mortar joints 960.

Although the invention has been described in terms of exemplaryembodiments, it is not limited thereto. Rather, the appended claimsshould be construed broadly, to include other variants and embodimentsof the invention, which may be made by those skilled in the art withoutdeparting from the scope and range of equivalents of the invention.

What is claimed is:
 1. A sill plate bracket for a basement wallreinforcement system comprising: an elongated flat surface; at least onespike with a pointed end; and at least one pilot hole.
 2. The sill platebracket for a basement wall reinforcement system as described in claim 1wherein the at least one spike is formed from a cutout piece of materiallocated within the elongated flat surface and the at least one spikeremains attached to the elongated flat surface.
 3. The sill platebracket for a basement wall reinforcement system as described in claim 1wherein the sill plate bracket is made of metal.
 4. The sill platebracket for a basement wall reinforcement system as described in claim 1wherein the sill plate bracket is made of a polymer.
 5. The sill platebracket for a basement wall reinforcement system as described in claim 1wherein the elongated flat surface has a width of two (2) inches and alength of six (6) inches.